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Injection molded plastic lenses have continuously improved their performance regarding optical quality and nowadays are as usual as glass lenses in image forming devices. However, during the manufacturing process unavoidable fluctuations in material density occur, resulting in local changes in the distribution of refractive index, which degrade the imaging properties of the polymer lens. Such material density fluctuations correlate to phase delays, which opens a path for their mapping. However, it is difficult to transfer the measured variations in refractive index into conventional optical simulation tool. Thus, we propose a method to convert the local variations in refractive index into local changes of one surface of the lens, which can then be described as a free-form surface, easy to introduce in conventional simulation tools. The proposed method was tested on a commercial gradient index (GRIN) lens for a set of six different object positions, using the MTF sagittal and tangential cuts to compare the differences between the real lens and a lens with homogenous refractive index, and the last surface converted into a free-form shape containing the internal refractive index changes. The same procedure was used to reproduce the local refractive index changes of an injected plastic lens with local index changes measured using an in-house built polariscopic arrangement, showing the capability of the method to provide successful results.

Simulation of imperfections in plastic lenses – transferring local refractive index changes into surface shape modifications